TABLE OF CONTENTS
Checking and repair: W-001/505
| Product: KB- starting motcr | Part no.s: 0 001 Gl. ... | Special features 102/11 Stiucture, usage I0G/1 General ~O5/1 Safety precautions 1106/1 Testers, fixtures, tools I08s/l Test specifications and settings I11l/l1 Tightening torques I14/1
Continue: [01/2
TABLE OF CONTENTS
Lubricants/lubrication chart I15/1 Electrical connections and circuit diagrams I16/1 Starting-motor disassembly table I18/1 Starting-motor disassembly Ii9g/i Cleaning of components I28/1 Checking, repair table IlIdg2/l Checking and repairing components II03/1 Conversion/repair of busbar IIIOQ9/1 Starting-motor assembly table III12/1
Continue: JI02/1
cance a I 01 |
| j | | Starting-motor assembly ITII13/1 |
SPECIAL FEATURES
These instructions describe the repairing of starting motors of type 001 41..
V/3.5 V/3.6 V/G.0 V/5.% V/6.6
The multi-plate clutch can no longer be repaired. A damaged or worn clutch is always to be renewed as a complete unit.
Continue: I02/2
SPECIAL FEATURES
KB starting motors as of date of manufacture FD G61 feature the following quality enhancement:
The busbar term. 30 and stud term. 50 are insulated on the inside of the starting metors by way of thermoplast encapsulation. Starting motors prior to FD 461 with the old norn-insulated version for terms. 30 and 50 must be converted to the new thermoplast- encapsulated version.
Continue: I03/1
ae
SPECIAL FEATURES
The checking of oilproof and water- proof starting motors is treated in separate instructions.
Starting motors may be operated with the combined start-locking and start- repeating relay.
Continue: I03/2 SPECIAL FEATURES
The functions of the combined start- locking and start-repeating relay are as follows:
* Start-locking function (Ccutout in the event of motor self-start, pre- vention of starting-motor actuaticn with engine running and after interruption of start command until engine has stopped)
Start-repeating function Cautomatic repetition of starting-motor actua- tion until pinion has engaged)
Continue : I01/1
STRUCTURE, USAGE
User prompting is provided on every page e.g.:
- Continue: I 17/1
- Continue: II 18/1 Fig.: II 17/2
Brief instructions may include several rows of coordinates. ore ar first coordinate row hip peer a second coordinate row 2S Oe rrr ar third coordinate row etc.
»--e-/7l = upper coordinate half ~ee/e2 = lower coordinate half
Continue: IO01/1
GENERAL
Expert repairs can only be performed with the prescribed tools and properly functioning measuring instruments. We therefore recommend that exclusive use be made of the tools indicated.
The use of incorrect and unsuitable tools and testers may result in injury
and could cause damage to the product and components.
Continue: I05/2
GENERAL
Make exclusive use of service parts as per the replacement parts list for the type of starting motor concerned.
To guarantee proper functioning, use must be made of the lubricants pre- scribed in these instructions before and during assembly.
Take care to ensure cleanliness when performing repair work.
Continue: IO1/1
SAFETY PRECAUTIONS
Component cleaning: Only use compressed air (max. % bar) and a clean rag to clean armatures, excitation windings, commutator
end shields, relays and the shaft ends cof the multi-plate ciutch. Do not use cleaning fluids.
Other parts, such as intermediate bearings and drive-end bearings, can be washed out in commercially available cleaners which are not readily flammable.
Take care not to inhale vapors.
Continue: I06/2
SAFETY PRECAUTIONS
Danger of fire: Avoid naked flames, light and sparks.
ATTENTION: Thoroughly dry cleaned components,
as gases may subsequently form in the sealed starting motor and cause
an explosion.
Always use tools indicated. The use of incorrect and unsuitable tools and testers could lead to injury.
Continue: [07/1]
SAFETY PRECAUTIONS
Pay attention to the following safety
regulations:
* Order governing work with flammable liquids (VbF) as issued by the German Ministry of Labor (BmA).
* Accident prevention regulations for electrical systems and equipment.
* Safety regulations for handling chlorinated hydrocarbons: - For companies: ZH 1/222 - For employees: ZH 1/129 as issued by the Main Association for Professional Liability Insurance Associations (Central Association for Accident Prevention and Industrial Medicine), Langwartweg 103, 53129 Bonn.
Continues: I07/2 SAFETY PRECAUTIONS
Outside Germany, pay attention to the appropriate local regulations.
Skin protection:
To prevent skin irritetion when working with oil and grease, apply hand cream before starting work and wash hands in soap and water after- wards.
Continue: I01/1
A08
TESTERS, FIXTURES, TOOLS
Listed in the following are all the tools required for repairing starting
motors of type KB.
Where tools used to be ordered by
way of type designation, indicated in parentheses.
Continue: 108/72
TESTERS, FIXTURES, TOOLS
Interturn short circuit
tester:
Test prods: Alternator tester WPG 012.00:
Cor Motortester)
Magnetic instrument stand:
Dial indicator:
Inserter and extractor for stud bolts:
Continue: [09/1
0 986
0 986
0 684
4 851
1 687
comm.
this is
619 110
619 114
291 200
601 124
233 011
avail.
TESTERS, FIXTURES, TOOLS
Torque wrench CO...70 Nm): comm. avail.
Spring balance
(O...160 ND): comm. avail. Torquemeter (O.15...0.80 Nm): 0 986 617 206
CKDAL 5485)
(33...300 Nm): 0 986 617 166 CKDAL 5476)
Clamping supports 0 986 619 362 CKDAW 9999)
Continue: I09/2 TESTERS, FIXTURES, TOOLS
Assembly wrench: 0 986 617 198 CKDAL 5483)
Extractor for needle
bushing in armatures 0 986 617 233 CKDAL 5492)
Spring collet 18.1 mm
for needle bushing in
armature: G0 986 617 240 CKDAL5492/0/7)
Pressing-in mandrel for
needle bushing in
armature: 0 986 617 185 CKDAL 54793
Pressing-out and pressing-in
mandrel for bushing in
commutator end shield: 0 986 617 190 CKDAL 5481)
Continue: I10/1
A09 => IT 09
TESTERS, FIXTURES, TOOLS
Pressing-out and pressing-in
tool for bushing and
cylindrical roller bearing
in drive end bearing: 0 986 617 101 CKDAL 5003)
Sleeve for supporting multi-
plate clutch when testing
overload provection: 0 986 617 164 CKDAL 54749)
Clamping sleeve for
holding armature in
three-jaw chuck: 0 986 617 232
. CKDAL 5491)
Continue: [10/2 TESTERS, FIXTURES, TOOLS
Thrust piece for holding
armature on
commutator saw: 0 986 617 224% CKDAL 5489)
Pole-shoe screwdrivers 0 986 619 393 CKDAW 9999/77) Torx T50 bit insert with hexagon 5/16": comm. avail.
Driving-in mandrel diameter: 84,50 - 0,05 mm Cimprovisation)
Continue: I01/1
TEST SPECIFICATIONS AND SETTINGS
Commutator minimum diameter: 47,5
Brush contact force: 20.2222 Armature axial play: 0,2...0,6 Clutcii-nut axial play: 0,9...-1;8 Initial force of
helical spring on
engaging shaft:
Final force of helical spring on engasing shaft:
Continues: I11/2
TEST SPECIFICATIONS AND SETTINGS
Eccentricity - Commutators: max. 0,93 mm - Laminated core: max. 0,05 mm
New carbon-brush dimension - Type A 76 Cnew version): 18,8 - Type N G2 Cold version): 26,5
Minimum carbon-brush dimension
- Type A 76 (Cnew version): 10,0 - Type N G2 Cold version): 16,5
Continues: I12/]
TEST SPECIFICATIONS AND SETTINGS Multi-plate clutch
Response torque of
overload protection:
Overrunning torques: 0,2.
Resistance, shunt winding C29 V/5.G KW): 960. C24 V/6.6 kW): 750.
C12 V/3.5 kW) 240. C12 V/3.6 kW) 22C. Cl2 V/4.0 kW) 160..
Continue: 113/71
Al2 SS I l2
TEST SPECIFICATIONS AND SETTINGS
Test specifications and settings for control relay 0 331 101...
Dimensions A and Bs: min. 2,0 mm Dimension Cs: min. 0,5 mm Dimension D: 0,8...1,9 mm Dimension E: min. 0,8 mm
Continue: IO1/1 Fig.: I13/72
KMS00073
AlG
TIGHTENING TORQUES
Pinion at
tachment:
Intermediate-bearing attachment:
Stud-bolt
attachment: Commutator end shield attachment: Control-relay attachment: Starting-motor solenoid attachment:
Pole-shoe screws:
Terminal Term. 30 Terminal Terminal Term. 31 Terminal Terminal
Continue:
30 (M10): (M10 only 30 (M12): 31 (M10): (M10 only 31 (M12): 50 (M6):
To1l/l
334)
- 334)
38.
Nm
Nm
Nm
Nm Nm
Nm Nm Nm Nm Nm Nm Nm Nm Nm
LUBRICANTS/LUBRICATION CHART
Generals:
Commutator and caroon brushes are to
be kept free of grease and oil. Greased parts are to be degreased before relubricating them.
€1): Fte vl 5 700 080 000 C2): Grease VS 10832 5 932 240 000 C3): Gleitmo 1580V 5 996 328 000 C4): Shell Tellus oil comm. avail.
Continue: I01/1 Fig.: 115/72
KMS00055
ELECTRICAL CONNECTIGNS AND CIRCUIT DIAGRAMS
Starting motors with shunt-field switch and ground return
= Excitation winding = Shunt winding
Control relay
Starting-motor solenoid
= SGhunt-field switch
= Start-locking and start-repeating relay
COU DWN H|
I = Shunt winding in series with armature Cas auxiliary excitation winding)
Shunt winding in parallel with armature Cas speed limitation)
Il
Continue: I17/1 Fig.: 116/72
KMSO00056
Al6 ae I 16
ELECTRICAL CONNECTIONS AND CIRCUIT DIAGRAMS
Starting motors with shunt-field switch and insulated return
Excitation winding
Shunt winding
Control relay
Starting-motor solenoid Shunt-field switch
Start-locking and start-repeating relay
tou dt Ww ot
Shunt winding in series with armature Cas auxiliary excitation winding)
Shunt winding in parallel with armature Cas speed limitatioan)
Continue: I01/1 Fig.: I17/2
KMS00057
.
ea a eo
Gee wn nn mseownne
STARTING-MOTOR DISASSEMBLY TABLE
Pinion disassembly I19/1 Control relay and starting-
motor solenoid disassembly T20/1 Carbon-brush disassembly T22/l Commutator end-shield
disassembly I23/1 Drive-end bearing disassembly I2G/1 Engaging shaft disassembly I25/1 Multi-plate clutch
disassembly I26/1
Continue: I01/1
STARTING-MOTOR DISASSEMBLY Disassembling pinion
Clamp starting motor in clamping support. Loosen Unistop pinion- fastening nut. Caunterhold with assembly wrench.
Remove pinion.
Clamping support: 0 986 619 362 Assembly wrench: 0 986 617 198
Continue: I20/1 Fig.: I19/2
KMS90058
ON
A19 = I 19
STARTING~MOTOR DISASSEMBLY
Disassembling control relay and starting-motor solenoid
Remove protective cap.
Loosen term. 30/31/50.
Lift off insulating cap (1) and loosen fastening screw.
Unfasten all screw and plug connec- tions at control relay and starting- motor solenoid.
Attention: Fixed cable connection (2) is only to be detached when replacing control relay/starting-motor solenoid. Detach connections at carbon brushes.
Continues: JI2l/l1 Fig.: I20/2
KMS00059
A20 ais I 20
STARTING-MOTOR DISASSEMBLY Disassembling control relay and starting-motor solenoid
Remove term. 31, connecting bar
term. 30 and insulators. Pay attention to O-rings and seal.
Loosen fastening screws (1) at
control relay and securing boit (2) at starting-motor solenoid.
Remove control relay and starting- motor solenoid together with term. 50. ATTENTION: DANGER OF INJURY
Engaging shaft is spring-pretensioned and shoots out of the armature on disassembling the starting-motor solenoid.
Continue: I2e2/1 Fig.: I2l/2
KMSOCO60
STARTING-MOTOR DISASSEMBLY Disassembling carbon brushes
Mark installation position of carbon brushes.
Use suitable tool to lift springs and remove carbon brushes.
Continue: I23/1l
STARTING-MOTOR DISASSEMBLY Disassembling commutator end shield
Mark position of end shield.
Loosen fastening nuts (1) and pull off commutator end shield.
Take care not to damage insulation of protruding winding ends (Cbend slightly if necessary).
Pay attention to shims on commutator end of armature shaft.
Continue: I24¢/1 Fig.: I23/2
KMS0O0061
STARTING-MOTOR DISASSEMBLY Disassembling drive-end bearing
Mark position of drive-end bearing. Pull drive-end bearing complete with armature and stud bolts out of stator frame.
Make sure stud bolts do not damage field windings.
Pull armature out of drive-end bearing.
Pay attention to thrust washer. Mark installation position of short stud bolt in drive-end bearing and use inserter and extractor tc disassemble stud bolts.
Inserter and extractor: comn. avail.
Continue: I25/1 Fig.: I24/e2
KMS00062
A25
STARTING-MOTOR DISASSEMBLY
Disassembling engaging shaft
Clamp armature in clamping support. Pull engaging shaft on commutator end out of armature.
Clamping support: 0 986 619 362
Continues: I26/1 Fig.: I25/2
KMS00063
| STARTING-MOTOR DISASSEMBLY
Disassembling multi-plate clutch
Loosen fastening screws (1) of intermediate bearing (2).
Remove intermediate bearing from clutch housing (3).
pS meinen commons waist th tr as a a tc it ops ages ph i tng iis hes
Continue: I27/1 Fig.: I26/2
_—
KMSO00064
STARTING-MOTOR DISASSEMBLY
Disassembling multi-plate clutch
toll complete multi-plate clutch our of clutch housing.
Continue: I01/1 Fig.,: I27/2
KMSO0065
| CLEANING OF COMPONENTS
Component cleaning: Only use compressed air (max. @ bar) and a clean rag to clean armatures, excitation windings, commutator
end shialds, relays and the shaft ends oi the multi-plate clutch. Do not use cleaning fluids.
Other parts, such as intermediate bearings and drive-end bearings, can be washed out in commercially available cleaners which are not readily flammable.
Take care not to inhale vapors.
Continue: I28/2
CLEANING OF COMPONENTS
Danger of fire: Avoid naked flames, light and sparks.
ATTENTION:
Thoroughly dry cleaned components,
as gases may subsequently form in the sealed starting motor and cause
an explosion.
Continue: IIOI1/1
a a a a
|
CLEANING GF COMPONENTS
Pay attention to the following safety regulations:
¥
Order governing work with flanmable liquids (VbF) as issued by the
German Ministry of Labor (CRBmA). Accident prevention regulations for electrical systems and equipment. Safety regulations for handling chlorinated hydrocarbons:
- For companies: ZH 1/222 - For employees: ZH 1/129 as issued by the Main Association
for Professional Liability Insurance Associations (Central Association for Accident Prevention and Industrial Medicine), Langwartweg 103,
53129 Bonn.
Continue: IIOQ1/2
CLEANING OF COMPONENTS
Outside Germany, pay attention to the appropriate local regulations.
Continues IQ1/1
a= II Ol
BO2
CHECKING, REPAIR TABLE
Checking pinion
Checking drive-end bearing Checking conimutator end shield
Checking carbon brushes Checking control relay and starting-motor solenoid Adjustine control relay and starting-motor solenoid Checking return force of helical spring on engaging shaft
Checking multi-plate clutch
Continue: II02/2 CHECKING, REPAIR TABLE
Checking arilling depth with extended drive spindle Checking needle bushing in armature
Replacing needle bushing
in armature
Checking armature for inter- turn short circuit, ground short and continuity Checking commutator
Checking excitation winding Replacing excitation winding
Continue: IQ1/1
II035/1 II0G/1
TiI07/l TI10/1
itis. II17/1
Il1i9/1 IIl2o0/1
Ii2¢/1 II25/1 TI26/1 IIl28/1 ITIO1/1
IIIO3/1 ITIToOs/1
II 02
CHECKING AND REPAIRING COMPONENTS Checking pinion Check pinion for running marks and
chipping. Replace if necessary.
Continue: IIOG/1
CHECKING AND REPAIRING COMPONENTS Checking drive-end bearing Cylindrical roller bearing (1),
radial lip-type oil seal (2) and bushing (3) must always be renewed.
Continue: JIIOS5/1 Fig.: IIOQG/2
KMS00066
BOG Prat II 04
CHECKING AND REPAIRING COMPONENTS
Checking drive-end bearing
Removal: Use pressing-out and pressing- in tool (1) to press out cylindrical roller bearing together with bushing. The gripping edges of the two jaws (2) must be inserted between radial lip- type oil seal and cylindrical
roller bearing.
Remove radial lip-type oil seal.
Pressingj-out and pressing-in tool for bushing and cylindrical roller bearing in drive-
end bearing: 0 986 617 101
Continues: IIO6/1 Fig.: IIO5/2
KMS00067
BO5 oe II 05
CHECKING AND REPAIRING COMPONENTS Checking drive-end bearing
Installation: Insert radial lip-type oil seal in drive-end bearing.
Use reversed pressing-out and pressing-in tool to press in cylindri- cal roller bearing and then bushing. Grease bearing.
Pressing-out and pressing-in tool for bushing and cylindrical roller bearing in drive-
end bearing: 0 986 617 101 Grease VS 1083ée: 5 932 24969 000
Continue: IIQ7/1 Fig.: 1106/2
KMSO0068
BO6 2 II 06
CHECKING AND REPAIRING COMPONENTS Checking commutator end shield
Check bushing for damage and running marks.
Removal:
Use pressing-out and pressing-in mandrel to press out bushing.
Pressing-out and pressing-in
mandrel for bushing
in commutator end
shield: 0 986 617 190
Continue: IIO8/1 Fig.: II07/2
KMSO00069
BO8
CHECKING AND REPAIRING COMPONENTS
Checking commutator end shield
Installation: Use reversed pressing- out and pressing-in mandrel to press in new bushing.
ATTENTION: Bushing must have been impregnated beforehand for 8 hours with Shell Tellus oil.
Pressing-out and pressing-in mandrel for bushing
in commutator end
shield: 0 986 617 190 Shell Tellus oil: comm. avail.
Continue: IIO9/1 Fig.: I108/2
KMS00070
LN SN ION
pl Des ry)
--- II
08
CHECKING AND REPAIRING COMPONENTS Checking commutator end shield Check all carbon-brush holders insulated against commutator end shield for ground short.
C"+" carbon-brush holders/insulated "-" carbon-brush holders)
Interturn short-circuit tester 0 986 619 110
Test prods Q 986 619 114
Ground-short test voltage: 80 V
Continue: II10/]
II 09
B10
CHECKING AND REPAIRING COMPONENTS Checking carbon brushes
Check tightness of cannections.
Check bearing surfaces for scoring
and chipping. Replace carbon brushes if minimum dimension has been reached.
New carbon-brush dimension
- Type A 76 Cnew version): 18,8 mm - Type N G2 Cold version): 26,5 mm Minimum carbon-brush dimension
- Type A 76 Cnew version): 16,0 mm - Type N G2 Cold version): 16,5 mm
Continues: II11/1
as It 10
CHECKING AND REPAIRING COMPONENTS
Checking control relay and starting- motor solenoid
Check tight ground connection of control relay and starting-motor solenoid. Ground connection must be bonded on with vibration-proof versions.
Individual components cannot be replaced. Replace scorched or
damaged control relays and solenoids. Always use the service parts given in the replacement parts list.
Continues: IIi1l/2 CHECKING AND REPAIRING COMPONENTS
Only starting-motor solenoids with shunt-field switch are now to be fitted.
When installing control relay
0 331 101 ... in starting motor with long excitation-wir.ding ends, these must be shortened by 7 mm by bending to form a loop.
Continues: II12/1
Bll mines II 11
CHECKING AND REPAIRING COMPONENTS
Checking control relay and starting- motor solenoid
In the case of starting motors produced Prior to date of manufacture FD Gé6l, the old, incompletely insulated version of terminals 30 and 50 must be con- verted to the new, thermoplast- encapsulated type.
A distinction is to be made between
two different situations:
Continues: II1l2/2 CHECKING AND REPAIRING COMPONENTS
For starting motors with M l2 thread at connection term. 30 perform conversion using:
- Parts set tm. 30,31 C2 9007 O11 069) - Parts set tm. 59 C2 007 O11 070) - Connecting bar tm. 30
For starting motors with M 19 thread at connection term. 390 perform conversion using:
- Parts set tm. 30,31 (€2 007 O11 069) - Parts set tm. 50 C2 007 O11 O70) - Connecting bar tm. 30
- New cemmutator end shield
Continue: I113/1
es II 12
ce O-——-
CHECKING AND REPAIRING COMPONENTS
Checking control relay and starting- motor solenoid
When installing insulated term. 50, electrical connection to control relay and holding winding of starting-motor solenoid must be re-established as follows:
Strip approx. 10 mm of cable.
Insert all three cables in end
splice (1), press together slightly and solder on. : Pull shrinkdown tubing (2) over end splice Cends of cables must not protrude out of shrinkdown tubing).
Continue: II14/1 Fig.: I113/2
KMS00071
B13 =e II 13
CHECKING AND REPAIRING COMPONENTS
Checking control relay and starting- motor solenoid
Fit new clip (3) (Cdisposable) at control relay. Clip must be seated in groove in strap of control relay. Insert insulated end splice into clip at control relay as far as it will go and squeeze clip together.
Continues: II15/1 Fig.: II14/2
KMS00072
B14 BES II 14
CHECKING AND REPAIRING COMPONENTS
Checking control relay and starting- motor solenoid
Control relay deenergized Dimensions A and B: min. 2,0 mm
Locking and release lever in rest position, locking lever slightly applied
Dimension C: min. 0,5 mm
Continue: II16/1 Fig.: II15/2
KMS00073
‘
we vases (= BARS
A EZ
B15 moles II 15
CHECKING AND REPAIRING COMPONENTS
Checking control relay and starting- motor solenoid
Armature retracted, release lever
in locked position
Dimension D: 0,8...1;4 mm Auxiliary contacts, control
relay deenergized Dimension E: min. 0,8 mm
Continue: II17/1 Fig.: I1I16/2
KMS00073
SS II 16
CHECKING AND REPAIRING COMPONENTS
Adjusting control relay and starting-motor solencid
Clean all contacts with contact file.
Check on wear reserve
Release lever (1) Ccatch) and latching lever of control relay
in end position (Cprimary current): Dimension a: 2,0...3,0 mm
Continues II18/i Fig.: IIi7/2
KMS00075
CHECKING AND REPAIRING COMPONENTS
Adjusting control relay and starting-motor solenoid
Actuator lever (2) of solenoid
in release position Ccontact with release lever (€1)). Remaining
travel of armature (3):
Dimension bs: 1,0...2,0 mm Bend actuator lever (2) if necessary. Pay attenti: to riveted joint.
N/O contact of shunt-field switch (4) must close 0,6...1,;2 mm before
end of stroke.
Continue: II19/1 Fig.: I1I18/e2
KMS00076
CHECKING AND REPAIRING COMPONENTS
Checking return force of helical spring on engaging shaft
This is performed with starting- motor assembled.
It must be possible to push pinion back into rest position with spring action via rubber buffer in thrust piece of starting-motor solenoid. Engaging shaft must be seated on ball (€1) in starting-motor solenoid in rest position.
Initial force: 35..-95 N Final forces: 60...70 N
Continue: IIT20/1 Fig.: I1I19/2
KMS00077
B19 ee It 19
B20
CHECKING AND REPAIRING COMPONENTS Checking multi-plate clutch
If the value for tne axial play of
the clutch nut, the overrunning torque or the response torque of the overload protection is outside the stated range, the entire multi-plate clutch must
be replaced.
Axial play: 0,9...1,8 mm Overrunning torque: 0,2...0,;9 Nm Response torque,
overload protection: 170...200 Nm
Continues: II21/1
ate II 20
CHECKING AND REPAIRING COMPONENTS Checking multi-plate clutch Check axial play of clutch nut.
Dimension a: 0,9...1,8 mm
Continue: II22/1 Fig.: IIte2l/e
KMS00151
B21 marae II 21
CHECKING AND REPAIRING COMPONENTS Checking muiti-plate clutch
Check overrunning torque of clutch. Clamp armature with clutch fitted in clamping support.
Insert pinion in drive spindle. Check overrunning torque of muiti- plate clutch with torquemeter in non-friction direction.
Torquemeters 0 986 617 206
Overrunnins torque: 0,2..-0,;4 Nm
Continue: II23/1 Fig.: II2e/e2
KMS00079
— e——>, wes 3
B22 cei II 22
CHECKING AND REPAIRING COMPONENTS Checking multi-plate ciutch
Check clutch overload protection. Slip support sleeve over drive spindle into intermdiate bearing and insert pinion in drive spindle. Use torquemeter to check response torque in friction direction.
Torquemeters: 0 986 617 )66 Support sleeves: 0 986 617 164%
Response torque, overload protection: 170...200 Nm
Continues: II24/1 Fig.: I123/2
KMSC0080
B2= pie II 23
| CHECKING AND REPAIRING COMPONENTS
Checking drilling denth with extended drive spindle
The drilling depth has to be checked an starting motors with extended drive spindle (shaft length approx. 80 mm). Dimension a: 44,0...%94,6 inm If necessary, fit shim between rubber bushing and pinion shaft.
Drive spindle Pinion shaft
Shim 3 100 100 O90 Rubber bushing
touou ut
DWN =
Continue: [125/1 Fig.: II24/2
KMS00081
CHECKING AND REPAIRING COMPONENTS Checking needle bushing in armature
Qnly replace needle bushing if bearing surface of bushing on drive spindle shows signs of wear, running- in or seizure marks, scoring or temperature-induced discoloration. The two annular lugs "a" and “b" have to be ground orf at the spring
collet before extracting the needle bushing.
The limit stop "c™ at the cone of the extractor must be tapered.
Continue: II26/1 Fig.: II25/2
KMS00082
B25 Pain Ii 25
CHECKING AND REPAIRING COMPONENTS Replacing needle bushing in armature
Removal:
Clamp armature in clamping support. Use extractor to pull out needle bushing.
Clamping support: 0 986 619 362
Extractor for needle bushing in armature: 0 986 617 2533
Spring collet 18.1 mm for needle bushing in armature 0 986 617 240
Continue: II27/1 Fig.: ITI26/2
KMS00083
CHECKING AND REPAIRING COMPONENTS Replacing needle bushing in armature
Installation: Grease needle bushing before pressing it in.
Use pressing-in mandrel (€1) to press needle bushing into armature such that needle bushing designation
can be seen from outside.
Pressing-in mandrel for needle bushing
in armatures: 0 986 617 185 Grease VS 10832: 5 932 2640 000
Continue: II28/1 Fig.: II27/2
KMS00084
CHECKING AND REPAIRING COMPONENTS
Checking armature for interturn short circuit, ground short and continuity
Check for interturn short circuit with tester and test probes. Check for ground short and continuity with tester and test preds.
Interturn short circuit tester: 0 986 619 110 Test prods: 0 986 619 114
Ground short test voltage: 80 V Continuity test voltage: 40 V
Continue: IIIO1/1 Fig.: II28/2
KMS00085
CHECKING AND REPAIRING COMPONENTS Checking commutator
Check commutator concentricity and turn down if necessary. Note minimum diameter.
To turn down, fit intermediate bearing and mount armature in three-jaw chuck using clamping sleeve (1).
Clamping sleeve: 0 986 617 232 Minimum diameters: 47,50 mm Eccentricity
- Commutator : max. 0,03 mm - Laminated core: max. 0,05 mm
Continue: ITIIO2/1 Fig.: IITI0l/2
KMS00086
C02
CHECKING AND REPAIRING COMPONENTS
Checking commutator
ATTENTION: On starting motors produced prior to date of manufacture FD G61 the lamination insulation of the commutator contains asbestos.
Use suitable extraction unit when working. The insulation is asbestos- free on starting motors as of FD G6l.
The lamination insulation of the commutator must be sawn out after turning down with a suitable tool.
Continue: IIIO2/2 CHECKING AND REPAIRING COMPONENTS
If commutator saw is employed, use must be made of a suitable extraction unit and the thrust piece for holding the armature.
Turn down commutator again after sawing out and check for interturn short circuit and ground short.
Note diameter.
Thrust piece: 0 986 617 224 Interturn short circuit
tester: 0 986 619 110 Test prods: 0 986 619 114 Minimum diameter: 47,5 mm
Ground short test voltage: 80 V
Continue: IIIO3/1
Pee Trtide2
CHECKING AND REPAIRING COMPONENTS
Checking excitation winding
Check each winding for ground short and continuity using tester and test prods.
Interturn short circuit tester: 0 986 619 110 Test prods: 0 986 619 114
Ground short test voltage: 80 V Continuity test voltage: G40 V
Continues: IIIOG/I1 Fig.: IIIO3/2
KMS00087
CO03 mos ITIO3
CHECKING AND REPAIRING COMPONENTS Checking excitation winding Use tester to check resistance values.
Alternator tester: 0 684 201 200 Cor Motortester)
Resistance, shunt winding
(2G V/5.4 kW): 960...1060 mOhm C24 V/6.6 kW): 750... 830 mOhm C€l2 V3.5 kW): 2640... 270 mOhm
Cl2 V/3.6 KW): 220... 250 mOhm Cl2 V/G4.0 kW): 160... 190 mOhm
Continue: IIIO5/1 Fig.: IIIOG/2
KMS00088 \)
C04 a TIIOG
CHECKING AND REPAIRING COMPONENTS Replacing excitation winding
Replace damaged; scorched or un- soldered windings.
Removal: Place stator frame in clamping support. Mark position of pole shoes. Loosen screws with pole-shoe screw- driver €1) and Torx insert (2).
Remove pole shoes and windings.
Pole-shoe screwdriver: 0 986 619 393 Torx T50 bit insert with he>.agon 5/16": comm. avail.
Continue: IIIO6/1 Fig.: IIIO5/2
KMS00089
Ca5 ae TIITO5
CHECKING AND REPAIRING COMPONENTS |
Replacing excitation winding
Installation: Warm excitation windings before fitting, insert with pole shoes in stator frame and slightly tighten screws.
Pay attention to markings.
Press in driving-in mandrel (1).
Driving-in mandrel diameters: 84,50-0,05 mm Cimprovisation)
Continue: IIIO7/1 Fig.: IITI06/2
KMS00090
C06 eS IIIO6
CHECKING AND REPAIRING COMPONENTS Replacing excitation windings
Place stator frame in clamping support. Finisn-tightening pole-shoe screws
and press out driving-in mandrel (1). Pole-shoe screwdrivers: 0 986 619 393 Torx T50 bit insert
with hexagon 5/16": comm. avail.
Tigntening torque Pole-shoe screws: G1...51 Nm
Continues: IIIO8/1 Fig.: IIIO7/2
KMS00090
Sane IT107
CHECKING AND REPAIRING COMPONENTS
Replacing excitation winding
If an excitation winding with short winding ends is installed ina start- ing motor with control relay
0 331 100 ... the relay must be replaced with the new version
C0 331 101 ...).
Continue: IOl]l/1
CONVERSION/REPAIR OF BUSBAR
KB starting motors as of date of manufacture FD 461 feature the following quality enhancement:
The busbar term. 30 and stud term. 50 are insulated on the inside of the starting motors by way of thermoplast encapsulation. Starting motors prior to FD 461 with the old non-insulated version for terms. 30 and 50 must be converted to the new thermoplast- encapsulated version.
Continues: 1109/2 CONVERSION/REPAIR OF BUSBAR
A distinction is to be made between the following two situations when converting starting motors prior to FD G61:
For starting motors with M le thread at connection term. 30 perform conversion using:
- Parts set tm. 30,31 (€2 007 O11 069) - Parts set tm. 50 C2 007 O11 070) - Connecting bar tm. 30
For starting motors with M 10 thread at connection term. 30 perform conversion using:
- Parts set tm. 30,31 £2 007 O11 069) - Parts set tm. 50 ‘2 007 O11 070) ~ Connecting bar tm. 30
- New commutator end shield
Continue: IIT10/1
COo9 as ITI09
CONVERSION/ZREPAIR OF BUSBAR
When installing insulated term. 50, electrical connection to control relay and holding winding of starting-motor solenoid must be re-established as follows:
Strip approx. 10 mm or cable.
Insert all three cables in end
splice (1), press together slightly and solder on.
Pull shrinkdown tubing (2) over end splice €Cends of cables must not protrude out of shrinkdown tubing).
Continues IIT11/1 Fig.: III10/2
KMS00071
CONVERSION/REPAIR OF BUSBAR
Fit new clip (3) (disposable) at control relay. Clip must be seated in groove in strap of control relay. Insert insulated end splice into clip at control relay as far as it Will go and squeeze clin tcgether.
Continue: I01/1 Fig.: III11/2
KMS00072
Cll == III11
Cle
STARTING-MOTOR ASSEMBLY TABLE
Assembling multi-plate clutch Assembling drive-end
bearing
Assembling commutator end shield
Checking armature axial play Assembling engaging shaft Assembling cambon brushes Assembling control relay and starting-motor solenoid Assembling term. 30/31/50 Assembling protective ca: Assembling pinion
Continues: I01/1
TII13/1 IIT15/1
TII17/1 IIT18/1 ITI19/1 IIIT20/1
IIt2l/l TiIr23/1 IIliI27/1 Iri2s/l1
IIItl2
STARTING-MOTOR ASSEMBLY Assembling multi-plate clutch
Lubricate as per lubrication chart before and during assembly.
Clamp armature in clamping support. Insert multi-plate clutch in clutch housing.
Clamping support: 0 986 619 362
Continue: III14/1 Fig.: III13/2 |
KMS00065
STARTING-MOTOR ASSEMBLY Assembling multi-plate clutch
Screw intermediate bearing (1) to clutch housing (C2).
Always use new, microencapsulated hexagon bolts (3) af strength class 10.9.
Use torque wrench.
Slip thrust washer (€4) onto inter- mediate bearing.
Torque wrench: comm. avail.
Tightening torques: 7,22--8,5 Nm
Continue: IJI15/1 Fig.: III14/2
KMS00091
Recs III14¢
STARTING-MOTOR ASSEMBLY
Assembling drive-end bearing
Screw stud bolts with short thread end and collar into drive-end bearing.
Pay attention to installation position mark of short stud bolt.
Insert armature in drive-end bearing.
Continue: III16/1
KMS000982
wiicast
=
. r~__
fiz fT —7
ea A
an ae
a
ae Hi
\ éy ; V 7 Ug 7
Fig.: I1115/2
STARTING-MOTOR ASSEMBLY Assembling drive-end bearing
Clamp stator frame in clamping support. Carefully insert drive-end bearing . complete with armature in stator frame. Pay attention to marking.
The stud bolts must not damage the field windings.
Clamping support: 0 986 619 362
Itil1i7/i
Continue: Fig.: III16/2
KMS00062
STARTING-MOTOR ASSEMBLY Assembling commutator end shield
Slip shims onto commutator end of armature shaft.
Assemble commutator end shield.
Pay attention to marking.
Use torque wrench.
When assembling end shield, take care not to damage insulation of protruding winding ends (Cbend slightly if necessary).
Torque wrench: comm. avail.
Tightening torque: 7.--8,8 Nm
Continues: III18/1 Fig.: III17/2e
KMS00093
C17 =e IITI17
cis
STARTING-MOTOR ASSEMBLY
Checking armature axial play
Adjust armature axial play on commutator end only by way of
shims.
Check freedom of movement of
armature.
Armature axial play:
Continue: IIJI19/1 Fig.:
KMS00094
0,2..-.0,6 mm
TIT18/2
IIiI18
STARTING-MOTOR ASSEMBLY Assembling engaging shaft
Insert engaging shaft from commutator end into armature until serrations of engaging shaft mesh with those of drive spindle.
If nmecessary, turn drive spindle at drive end.
Continue: III20/1 Fig.: TII19/Ze2
KMS00095
STARTING-MOTCR ASSEMBLY
Assembling carbon brushes
Use suitable tool to lift springs and insert carbon brushes. Pay attention to installation position mark.
Use spring balance to check brush contact force.
Spring balance C(O..-160 WN): comm. avail.
Brush contact force: 20...22N
Continue: JIIT21/1 Fig.: IIrl20/2
KMS00096
C20 ae III20
STARTING-MOTOR ASSEMBLY
Assembling control relay and starting-motor solenoid
Fit control relay and starting-motor solenoid. Use torque wrench. ATTENTION: DANGER OF INJURY
Engaging shaft is spring-pretensioned and shoots out of armature on removing starting-motor solenoid.
Torque wrench: comm. avail. Tightening torque
Hexagon bolts: l11...16 Nm Securing bolts: 9,8...-14 Nm
Continue: III22/1l Fig.: IIltel/2
KMS00097
es TII21
STARTING-MOTOR ASSEMBLY
Assembling control relay and starting-motor solenoid
Make all electrical cennections as per terminal diagram at control relay and starting-motor solenoid. Ends of field Winding must lie flat on connections of control relay.
Bend slightly if necessary.
Secure carbon-brush connections.
Pay attention to different screw lengths.
Continues: JII2e3/1 Fig.: III22/2
KMS00098
C22 Ss IIt22
C23
STARTING-MOTOR ASSEMBLY
Assembling term. 30/31/50
Insert connecting bar term. 30 and stud term. 50 in insulating plate
with seal.
Slip O-rings over stud term. 30/50
and insert in commutator end shield. Slip O-ring over stud term. 31 and insert in commutator end shield. Ensure proper fit of seal and O-rings. Slip sleeve over term. 31.
Continues: III23s/2 STARTING-MOTOR ASSEMBLY
Attach insulator, washers, spring lock washers and hexagon nuts. Attach connecting bar term. 30 to control relay and fit insulating cap.
Tightening torque
Terminal 30 (M10): 16...20 Nm Term. 30 (M10 only ...3394): 14...16 Nm Terminal 30 (M12): 25...31 Nm Terminal 31 (M10): 16...20 Nm Term. 31 (M10 only ...339): 14...16 Nm Terminal 31 (M12): 25...31 Nm Terminal 48 (M5): 2,6..-3,5 Nm Terminal 50 (M6): 3,5..-%,5 Nm
Continue: III246/1
ve ITI23
STARTING-MOTOR ASSEMBLY Assembling term. 30/31/50 Terminal 30:3
Connecting bar term. 30 Inner insulating plate Seal
O-ring
Outer insulator
— = — — — = — =
Continues: III25/1 Fig.: III24/e2
KMSO00099
STARTING-MOTOR ASSEMBLY Assembling term. 30/31/50
Terminal 31:
6 = Stud term. 31
G4 = O-ring
5 = Outer insulator 7 = Sleeve
Continues: III26/1 Fig.: III25/2
KMS00149
C25 Pree Tit2s
STARTING-MOTOR ASSEMBLY
Assembling term. 30/31/50
Terminal 50: Stud term. 50
Inner insulating plate O-ring
Outer insulator
ui BN ® hoe one it
Continues: III27/1 IIt26/e2
Fisg.:
KMS00159
LI OTN
aa eee
C26 a
C27
STARTING-MOTOR ASSEMBLY Assembling protective cap
Fit and secure protective cap. Use new seals for commutator end shield and fastening screws.
Continue: III2871
piace. Lee
STARTING-MOTOR ASSEMBLY Assembling pinion
Insert pinion in drive spindle and secure with new Unistop nut.
Use torque wrench.
Counterhold with assembly wrench.
Torque wrench: comm. avail. Assembly wrench: 0 986 617 198 Tightening torque: 38...43 Nm
Continues: I01/1 Fig.: TII28/e
KMS00058
EDITORIAL NOTE
Copyright 1996 ROBERT BOSCH GmbH Automotive-Equipment After-Sales Service
Technical Publications Department KH/VDT,
Postfach 30 O2 20, D-70422 Stuttgart
Published bys
After-Sales Service Department for Training and
Technology (CKH/VSK).
Time of going to press 02.1996. Please direct questions and comments concerning the contents to our authorized representative in your country.
Continue: IVOl/2
EDITORIAL NOTE
The contents of this microcerd are intended only for the Bosch Franchised After-Sales Organization. Passing on
to third parties is not permitted.
Microfilmed in the Federal Republic of Germany.
Micropnotographié en République Fédérale d'tAllemagne.
Continues: IO01/1